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System Level Design Presentation
12.07.06
Mobile Device Charger
Sponsored by
Liaison:
Coach:
Team:
Len Horey
Wenhsing Wu
Alex Rodriguez
Bryan Talenfeld
Niraj Patel
Peter Flores
“Pree” Silva
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
2
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
3
Project Background
• Develop a device to charge the following
common handheld electronics:
– Cell phones
– PDAs
– MP3 players (especially iPods)
• Primary Customer Needs
– High value to end-user
– Easy to use
– Minimum liability
– Minimum number of attachments
• Major Constraints
– Avoid patent infringements
– Strive to cover 80% of market
4
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
5
Previous Accomplishments
• Verified need for product
– Identified end-user habits and practices
• Established target device market
– Identified device brands that will cover
desired market share of 80%
– Categorized devices by voltage and current
inputs
• Created patent database
– Compiled relevant active patents
– Established simple summaries for ease of use
6
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
7
Current Accomplishments
• Acquired extended knowledge of chargers
– Reverse engineered similar chargers
– Completed external research
• Completed hardware design
– Revised concept
– Circuit design and schematics
• Prototype Plan
• Testing Plan
8
Current Accomplishments
Revised Concept
Charging
Device
Charging
Indicator
/LED
Power
Battery
Wall (AC)
Existing
Device
“Charging”
Fully
Charged
Output
Selection
Processor Attachments
Static
Outputs
Individual
Cable
Circuit
Slow
Charge
Rapid
Charge
Overcharge
Protection
Must withstand:
- Temperature: 50 to 90 degrees Fahrenheit
- Humidity: 25 to 95% RH
- Constant use and possible abuse
9
Current Accomplishments
Hardware Connections
Wall (AC)
Mobile device
(cellphone)
Overcharge
Protection
USB Port
Device
Adapter
10
Current Accomplishments
Circuit Design and Schematics
11
Current Accomplishments
Overcharge Protection
• This circuit has the goal of protecting the
device from overcharging
• Still under development
to achieve ideal conditions
12
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
13
Prototype Plan
• Assembly
– The Prototype is divided into two parts:
• DC supply
– AC  DC using transformer, Wave rectifier and
voltage regulator. DC voltage at the USB receptacle
• Attachment
• Testing
– The USB connector is followed by charge
termination circuit and then connected to device
connector through a wire.
- DC supply
- For voltage and current available at USB output
- Attachment
- For functionality of the charging termination
circuit. Also test its functionality with computer
USB ports.
14
Prototype Plan
Parts, Quantity and Cost
Bill of Material
12/3/2006
Subcom
ponent
Part Name
NPN BJT
Resistor
Attach ments
Capacitor
Phone
Connector
Male USB
Adaptor
Capacitor
Transformer
DC
Supply
Full-Wave
Bridge
Rectifier
Voltage
Regulator
Female USB
Connector
Description
Value
Vendor
Man. Part Number
Manufacturer
Name
1%, 1/4 W MF
1%, 1/4W MF
5%, 1/2W CF
10%, 10V, Ceramic
N/A
54.9
1.78k
5.1
10uF
Allied
Allied
Allied
Newark
2SC2655-0(F)
RNF1/4T1 54.9 1%
RNF1/4T1 1.78k 1%
CF1/2 5.1 5%
0202ZD103KAT2A
Toshiba
SEI
SEI
SEI
AVX
20%, 25V, Al. Elec. 10uF
20%, 25V, Al. Elec. 1000uF
Primary: 115/230
10V,1A
50/60 Hz, VA 10
Dpak,Vin 40V max,
Vdrop 2V
5V,
500mA
Allied
925
Keystone
Electronics
Allied
Allied
SEK100M025ST
SEK102M025ST
Mallory
Mallory
Allied
VPP10-1000
Triad Magnetics
Newark
MC78M05CDTG
ON Semi
Allied
787616-1
AMP/Tyco
Electronics
Width Length
0.1
0.1
0.11
0.0122
Total
Area
0.25
0.025
0.25
0.025
0.35
0.0385
0.024 0.000293
0
Total Area
0.2
0.2
0.51
0.51
1.875
0.088793
0.04
0.2601
1.375 2.578125
0
Total Area
Estimated Cost of DC Supply: $11.76
Estimated Cost of Attachments: $1.94
3.055811
Unit Price
Qty
Total
Price
$0.2100
$0.0600
$0.0600
$0.0600
$0.2860
1
1
1
1
1
$0.2100
$0.0600
$0.0600
$0.0600
$0.2860
$0.5000
1
$0.5000
$0.7600
1
$0.7600
TOTAL
$0.0500
$0.2900
1
2
$1.9360
$0.0500
$0.5800
$10.0200
1
$10.0200
1
$0.0000
$0.4800
1
$0.4800
$0.6300
1
$0.6300
TOTAL
$11.7600
15
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
16
Testing Plans
Quality/Reliability Objectives
• Meet company specifications
• Meeting company/government standards for
quality and reliability
• Assuring that the components and sections of
the product are reliable under stressed
conditions.
• Testing product for previously stated condition:
– Product Maltreatment Test
17
Testing Plans
Product Maltreatment Test
• This is designed to test the durability of the
prototype.
• The test involves the following:
– Pulling the attachment cord when phone
is connected
– Trying to force wrong attachment into
the phone
– Verifying part life by running various
short and long term tests.
18
Testing Plans
Product Verification Plans
• The hardware of the product will be main
focus when running verification tests.
• No software is required in our product
minimizing the testing needed for
hardware/software integration.
• The following testing procedures will be
used to test the product:
– Test Battery Condition
– Charge Regiment Test
19
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
20
Issues
• Attachments
– The team has not been able to find a
vendor for the cell-phone, PDAs and MP3
player connectors needed to connect the
charger to the mobile devices.
21
Agenda
• Project Background
• Previous Accomplishments (up to PDR)
• Current Accomplishments (since PDR)
– Revised concept
– Circuit Design
•
•
•
•
•
Prototype Plans
Testing Plans
Issues
Next Steps
Questions
22
Next Steps
•
•
•
•
•
•
•
Order Components
Independent work
Receive Components
Prototype Build Start
Prototype Build End
Testing/ Debugging Start
Testing/ Debugging End
12/11/06
12/11-01/08
01/08/07
01/10/07
01/22/07
01/22/07
03/01/07
23
Questions
Bryan
Alex
Neil Pree
Peter
24